First output of “Raw” foil on JSC KMEZ
At JSC Kyshtym Copper Electrolytic Plant in the Copper Foil Electrodeposition division, that is currently still under construction, the first two ED-cells by Japanese manufacture NEW LONG MACHINE WORKS, Ltd were put into operation.
A lot of preparatory work has been done prior the test start-up. First of all, the unit for electrolyte preparation was commissioned, before that, all the tank equipment of the unit was tested for resistance to a highly aggressive acid medium which is necessarily to avoid the electrolyte contamination with foreign metals which might be formed as a result of sulphuric acid impact on the tank. For three days sulphuric acid solution was circulated through the tanks, concentration of the sulphuric acid were gradually increased until it reached 100g per litre. At the same time, the chemical composition of the solution were constantly monitored for iron, chrome, nickel, molybdenum and other impurities content.
Test results confirmed reliability of the tank equipment manufactured by Remservice, LLC and allowed to proceed with the process solution preparation which includes copper rod dissolving with constant monitoring of dissolution rate and electrolyte solution chemical composition.
On Friday, November 13, everything was ready for the trial run of the equipment. Date and time of the start-up were coordinated with KONTEX INTERNATION Inc. specialists (in charge of basic engineering ) and NEW LONG MACHINE WORKS, Ltd. specialists (equipment manufacturer) in order to make it possible for them to take part in this process in the videoconference mode. Beforehand, with their remote participation, technician stuff of the foil production division unpacked and installed drum-cathodes on the ED-cells.
At the appointed hour, electrolyte were supplied to one and then to the other ED-cell, current load was turned on – the first yield of “raw” foil was electrodeposited on the drum-cathode.
Electrodeposited copper foil production is a very complicated and demanding process, with lots of tricks. Risk that something could go wrong during test run and that it might not be possible to obtain raw foil was very high. However test run exceeded every expectation: the equipment were running as if it was commissioned just after a short shutdown. Taking into account the fact that due to Coronavirus restrictions ED-cells were installed by plant technician stuff by themselves and Japanese installation supervisors took part in it only in a remote mode, it could be definitely said that the plant coped with the set tasks
For the test run it was selected to produce 35 micron foil as it is easier to further test manufacturing parameters on this foil. The first 8 metre piece was received and manually rolled into a roll. It is immediately enlarged plant museum collection. It was signed as: “The first piece of electrodeposited copper foil from the new foil production division, Kyshtym, 13.11.2020 »
Meanwhile, ED-cells continued functioning and producing rolls with a length of 2,500 meters — the production of such a roll takes about 20 hours on average. Foil produced during the trial run is needed for commissioning and test run of the Treater, slitting and cutting machines. In addition, these first foil samples are thoroughly studied in the plant laboratory. Their chemical composition, physical and mechanical properties will become the starting point for further improvement, for maximum approximation to the declared technical specifications, for quality compliance with the individual requirements of each customer.
— Undoubtedly, the trial run highlighted certain issues of the equipment operation. Now they are being actively discussed with our foreign partners in order to avoid any surprises in the future, — comments Andrey Kudryavtsev, General Director of JSC KMEZ. — We have to put into operation more no less complex equipment, and then coordinate operation of the entire technological chain. There is a lot of work ahead, but a trial run showed that our team can handle it.
KMEZ will be the only Russian manufacturer of electrodeposited copper foil with a thickness of 9 to 105 microns, which is used for the manufacture of printed circuit boards of any complexity class for electronics and instrumentation – from smartphones and household appliances to aircraft construction, as well as for lithium-ion batteries.
